Multi-Purpose Chamber Furnace Unit

Multi-Purpose Chamber Furnace Unit

The Universal Heat Treatment Plant

The Universal Heat Treatment Plant

AICHELIN Ges.m.b.H.
Postfach 210
A-2340 Mdling
Phone (+43) (2236) 236 46 - 0
Telefax (+43) (2236) 22 22 9
info@aichelin.at

NOXMAT GmbH
Ringstrae 7
D-09569 Oederan
Phone (+49) (37292) 65 03-0
Telefax (+49) (37292) 65 03-29
info@noxmat.de

SAFED SUISSE SA
36, rue Emile-Bochat
CH - 2800 Delmont
Phone (+41) (32) 421 44 60
Telefax (+41) (32) 421 44 64
contact@safed.ch

AICHELIN Service GmbH

Postfach 340
D-71603 Ludwigsburg
Phone (+49) (7141) 6437 - 0
Telefax (+49) (7141) 6437 - 100
info@aichelin.de

AICHELIN Heat Treatment

Systems (Beijing) Co. Ltd.
10 00 86 Beijing, China
Phone (+86) (10) 8255 1421
Telefax (+86) (10) 8255 1020
aichelin@china.com

EMA Indutec GmbH

Petersbergstrasse 9
D-74909 Meckesheim
Phone (+49) (6226) 788 - 0
Telefax (+49) (6226) 788 - 100
info@ema-indutec.de

Standard-Line
Individual-Line

http://www.aichelin.com
Subject to technical changes
AICHELIN, NOXMAT, NITROC, ENDOMAT, FLEXICLEAN
are registered trademarks

TI02-01/Mrz2010/E

AICHELIN Multi-Purpose Chamber Furnace Unit

References

1. Introduction
During the last decades, AICHELIN Group has built far more than 1000 protective gas
chamber furnaces and put them into operation. Most of these plants provide their
service reliably this very day. This impressively proves the permanent high quality,
reliability and economy of these plants. Due to the central meaning of this furnace type,
it is being permanently developed and constantly held together with our customers on
the highest state of the art. This has now resulted in the creation of three series, where
each of them is optimally aligned to your needs. :

Standard-Line

The low cost series with superior components.

Further description within this folder.

Individual-Line

Powerful and worth every Cent. If the standard line does not meet your requirements at
100%. Also described here

Evolution-Line

The series, that fits into EVERY existing chamber furnace plant. Description see separate
folder.

2. Application range of the Multi-Purpose

Chamber Furnace

Gas Carburizing

C
Temperature

Possible modes of heat treatment:

For example:
! gas carburizing
- with direct quenching
- with intermediate cooling
- with charge cooling under
protective gas
! re-carburizing
! carbonitriding
! NITROC - nitrocarburizing
! nitriding
! hardening in oil or salt
! normalizing
! annealing
! tempering

C-Level

t
C

Gas Carburizing with Intermediate Cooling

Temperature
C-Level

t
Annealing

Normalizing
Various annealing programs

Temperature

Temperature

C-Level

When are Chamber Furnaces preferentially used?

!
!
!
!
!
!
!
2

for small and middle capacities

for different heat treatment procedures
for different kind of parts and high diversity of parts
at charge weights of appr. 150 - 1800 kg (even more in special cases)
if flexibility is required
for different production requirements
if quality with economy is required

19

3.

Design of a Multi-Purpose Chamber Furnace Units

3.1

Quality features of the Multi-Purpose Chamber Furnace at AICHELIN

to reach heat treatments with high quality and economy

extremely good temperature uniformity (10 K) and accuracy, simple

operation

fully automatic and reproducible heat treatment

high reliability of the production process with long life cycle

low energy and media consumption

low pollutant and noise emission

short transport cycles from furnace into the oil bath: according to the

furnace size, 15 20 sec..

Tray transport device in cold vestibule

with implementation of the air/oil cooling system: NO COOLING WATER at

the furnace plant required!

exact process documentation

3.2 Sizes of the AICHELIN Chamber Furnace

Standard-Line
size *1
500 (3)
800 (4/2)
1100 (5/2)
XXL (5/3)

size of the charges

WxLxH in mm
600 x 1100 x 650
700 x 1300 x 850
900 x 1500 x 850
900 x 1500 x 1300

gross charge
max. kg
650
1200
1500
1800

Individual-Line
size *1
300 (2)
600 (4/1)
800 (5/1)
1000 (4/3)

size of the charges

WxLxH in mm
500 x 900 x 650
700 x 1300 x 650
900 x 1500 x 650
700 x 1300 x 1150

gross charge
max. kg
500
1000
1200
1200

*1

sizes in () old description

Further dimensions and charge weights on request

3.3 Possible design types of the Multi Purpose Chamber Furnace

Pre-Chamber Furnace [VKE(G)s]

Continuous Chamber Furnace [DKE(G)s]

Continuous Double-Chamber Furnace [2KDKE(G)s]

3.4 Constructive characteristics of the AICHELIN Chamber Furnace

! constant insulation of the furnace chamber without apertures or channels
! thick, well-insulating, tight furnace door
! abundantly dimensioned oil bath with multi-level oil bath circulation,

optimized in streaming
! modern measure-, switch and control unit for memory of automatic

heat
treatment procedures and with all required safety and monitoring devices

4. Accessory equipment for Multi-Purpose Chamber Furnaces

4.1 Chamber- and Stress
Relieving Furnace
without protective gas

:
C
NEW
o 700
t
p
u
now

Furnace temperature max. 500 C

VKHLE
electrically heated
as tempering-, relieving and
pre-heating furnace

VKHLG gas heated

as pre-heating furnace
4.2 Chamber Furnace
without protective

Furnace temperature max. 750 C

KE
electrically heated

KG
gas heated
4.3 Chamber Furnace for
protective gas

Furnace temperature max. 750 C

Kes
electrically heated

Kgs
gas heated
with charge cooling device
Optional: "NITROC" - nitrocarburizing device

4.4 Chamber Retort Furnace

Furnace temperature approx. 700 C

KREs

electrically heated

with forced charge cooling device

(cooling with nitrogen) for
-

nitrocarburizing
water-/steam oxidation
gas nitriding
annealing and tempering under
nitrogen
- bright annealing
- deep cooling up to -120 C

4.5 Chamber-Immersion-Spraying-Washing Machine

KEKTE
KEKTG
KEKTD

electrically heated
gas heated
steam heated

for high-quality washing processes in

aqueous solutions
- with dipping and spraying system
- two washing liquid containers
- drying device by vent condensor (optional)

s
:
ow-co
l
s
a
NEW
e
l
vailab er
now a
wash
g
n
i
y
a
spr

4.6 FLEXICLEAN -Chamber-Washing Machine

EKFE
EKFG
EKFD

electrically heated
gas heated
steam/hot water heated

for high-quality washing processes in

aqueous solutions (especially with neutral
cleaners) with two washing liquid
containers (option: third container)
with vacuum boiling Vacupearl,
spraying and flotation system and
vacuum drying device

4.7 Charging- and Discharging Cart

for one-sided or opposite designed layout

Optional: lifting function for

two-layer charge storages

5. Exemples of Installations for Mulit-Purpose Chamber Furnaces

5.1 Chamber Furnace Line for agriculural machine gears, gas heated
Tray 1100x600x600 mm (LxWxH), max. 650 kg gross

5.2 Chamber Furnace Line for gear parts, gas heated

Tray 1300x700x800 mm (LxWxH), max. 1000 kg gross

5.3 Chamber Furnace Line for gear parts, gas heated

Tray 1300x700x800 mm (LxWxH), max. 1000 kg gross

5.4 Chamber Furnace Line for salt bath hardening of ball bearing parts
Tray 1500x900x800 mm (LxWxH), max. 1200 kg gross

5.5 Continuous Chamber Furnace Line for gear parts, gas heated
Tray 1500x900x1250 mm (LxWxH), max. 1800 kg gross

10

6. Technical description of the Pre-Chamber furnace Type VKE (G) s

The Multi-Purpose Chamber Furnace
consists of following components:
6.1 Furnace Chamber:
The furnace chamber consists of a gas
tight furnace housing and lining of
high-quality insulating material. The
ceramic hearth made of siliconcarbide bricks, possesses a large open
space for the gas flow. The optional
silicon carbide gas conduction muffle
and the intensively working gas
circulation aggregate ensure a
continuous flow of the charge and an
outstanding temperature uniformity. The gas circulator is very compact due to the
flange execution with extended motor shaft. The shaft sealing to the furnace is done
by means of oil collecting main. By the closed oil cooling circuit with thermosiphon
effect, cooling of the engine mount also works without current supply! The
intermediate door is closely fit to the furnace chamber. Maintenance platforms on the
furnace chamber are standard with Aichelin.
6.2 Heating:
Heating is done by vertically installed radiant tubes, optionally electrically or with gas.
For gas heating, automatic gas burners (type Aichelin NOXMAT) with recuperative
preliminary heating are used. These do have a high firing-technical efficiency. A
variable switching cycle ensures highest temperature uniformity. With gas heating, the
radiant tubes can be used as condenser tube for the rapid lowering from carburizingto hardening temperature. Thus, a shortening of the total heat treatment time results.
For excess temperature control, there is an own over-temperature safety
thermocouple between two radiant tubes, which protects the radiant tubes against
overheating.
6.3 Vestibule Chamber - Quenching Tank:
At the furnace chamber, the vestibule chamber with oil bath is attached gas tight.
The vestibule chamber can be used additionally for charge cooling down to
discharging temperature or for intermediate cooling (isothermal annealing).
Therefore, a separate cooling equipment with own heat carrier oil-cooling circuit
via gilled pipe heat exchangers is provided. For the support of the charge cooling
procedure, a gas circulation aggregate with guiding muffle is installed. Optionally,
the oil bath- and vestibule cooling can be equipped with oil/air heat exchangers.
Thus, no cooling water is required at the plant.
The vestibule door is pressed via cranks by control shafts through a gear motor
with spring pressing device into the door seal.
Underneath the vestibule door, a supervised flame curtain device, automatically
firing by piezo ignition is implemented. The flame curtain must be ignited, only
then the outer door can open. The oil bath volume of the hardening container is

11

optimally adapted to the charges. The double-walled housing execution with oil
detector safely avoids environmental-damaging oil leakages.
The oil level in the hardening container can be supervised by a minimum-maximum
indication. Oil cooling is done by means of heat exchangers (oil/water or oil/air).
The oil bath heating is carried out electrically by dipping heating elements. The oil
circulation is reached by means of two oil circulation aggregates with two
adjustable numbers of revolutions.
Via oil guidance channels and oil guide plates, attached closely to the charge, a
targeted, obligatory flow of the charge takes place. This is particularly important
with closely packed charges for a constant hardening result.
Depending upon need, the hardening bath can be equipped additionally with
intensified oil bath circulation capacity and with program controlled continuously
adjustable circulation capacity of the oil bath circulation aggregates.
6.4 Lowering platform, charge transport:
The lowering platform is carried out in two layers, thus you can charge the furnace
again , while a charge stays in the oil bath. In the vestibule chamber, the automatically
working tray transport equipment is implemented.
The cooperation of the high speeds of lowering platform and intermediate transport
results in very short moving times; for example for the multi purpose chamber furnace
size 3: start from the furnace chamber up to complete immersing into the oil bath
approx. 15 seconds.
All drives are carried out by electrical motors with safe end position. Hand wheels are
provided for the first drive adjustment and for the emergency operation.
6.5 Safety device:
In order to save the charge from damage with power failures resp. with
disturbances, the multi purpose chamber furnace is equipped with an automatic
N2-safety gas supply device.
Further, all failures of energy supply, disturbances of the drives, heating etc. are
signalized as failure report.
6.6 Gas supply:
The multi purpose chamber furnace can be designed with different kinds of gas
supply. Endogas, N2-methanol or direct gas supply with air, propane, natural gas or
acetone are used as protective gases.
As additional gases, propane, natural gas, LPG gas, acetone and other liquid
carburizing media can be used.
The automatic control of the carbon level is done according to standard by oxygen
probe (alternatively by Lambda probe).

12

7. Chamber-Furnace Continuous and Continuous Double-

Continuous Chamber Furnace [DKE(G)s]

Continuous Double-Chamber Furnace [2KDKE(G)s]

The furnace types are, regarding the components, essentially equal to the prechamber furnace. Charge transport takes place according to the continuous principle.
With the continuous chamber furnace, the charge is pushed into the first chamber by
the charging table. With the double chamber furnace, likewise from the charging table
into the first chamber and afterwards into second (with slightly opened outer door).
Charge transport into the oil bath is done by the transport equipment of the vestibule
chamber.
The continuous double chamber furnace has an own temperature and C-levelregulation for each zone. An intermediate door separates both furnace chambers.

13

8. Control system of a Multi-Purpose Chamber Furnace

8.1 Control:
The control level is divided into 3 operation modes:
setting mode
manual mode
automatic mode
Automatic mode
In this mode, the furnace is operated in normal production. After the first start, all
movements of the furnace are executed in correct series ,and for optimising the
time partially even in parallel.
A full graphic operator panel is the central operation element of the furnace.
It displays all limit switch conditions and the conditions of the sequencers.
All continuously running devices (fans, pumps, etc.) are also controlled by this operator
panel.
On the overview screen (see below), the condition of the plant is shown in form of an
animated picture.
Therefore, at any time an overall picture of the plant is visible and secures a simple
operation of the furnace.
On these overview pictures, the position of the charge and all actual states of the
drives, as well as the actual and standard value indication for C-level and temperature
are displayed.

14

Connection to superordinate system

FOCOS I - process control system

Process control system

8.2 Controlling:
Color printer
Temperature control of the
annealing chamber, of the oil
bath as well as C-level control is
done by means of a compact
OP 270
controller. Communication with
the programmable logic control
Annealing
(PLC) by bus system (Profibus
chamber
DP). With standard operation,
the set values are preset by the
PLC and the actual values
indicated back to the PLC.
Oxygen sensor
These values are displayed at
Heating chamber
the operator panel.
The protection against
exceeding of the allowed
Oil bath
maximal temperature of the
furnace is effected by an excess
temperature signal device.
Falling below the safety temperature at gasified furnace is supervised by two safety
temperature signal devices.
The oil bath is protected against exceed of the allowed maximal temperature by rod
temperature controller.
C-level control of the furnace is done by a special software in a compact controller.
Regulation and control of the gas feeding is independent from the programmable
logic control.
At the operator panel, complete heat treatment programs are put menu-driven.
After charging and start of the required heat treatment program, the PLC takes over
the function of the programmer.
The set value is preset to the temperature/C-level-controller due to the stored
program set values.
The PLC also takes over the control of the quenching processes (oil resp. gas
quenching).
Recording of annealing chamber temperature, C-potential and temperature of oil
quenching is done by a 6-channel printer.
SPS / S7-300: movement control,
fault recording

Compact controller-PMA: temperature, C-potential

Input of heat-treatment-programs,
operation of the plant

Excess temperature
- signaling device

6-channel recorder for

temperatures and C-potential

2x safety-temperature signaling device

Supply gas

Air

Excess temperature protection

with rod-temperature-controller

8.3 C-level control:

This is effected by C-level, measuring and switch system CARBOMAT S7 with
extended software for temperature and C-potential-time profile. The actual values are
recorded by an oxygen probe (measurement of the gas atmosphere in the furnace via
zircon oxide).
Fault signals are intended for sensor loss, soot border achieved, as well as for
minimum and maximum limit values.
Alternatively, the C-level-regulation can be carried out with software controllers of
other selected measuring technology companies.

15

9. FOCOS-I process control system for chamber furnaces

With a FOCOS-I system, several chamber furnaces can be controlled.
With starting of a heat treatment program, the entire information is sent to the to the
programmable controller (PLC)of the furnace plant . Afterwards, the FOCOS-I system
controls the program sequence and sends the standard values to the PLC. This passes
the standard values on to the compact controller. The current actual values of
temperature and C-level are recorded to the FOCOS-I system. The program sequence
can be pursued on-line via operator panel .
If there were a loss of the FOCOS-I system during a heat treatment , then the PLC of
the furnace plant immediately takes over the programmer function and the program
can be continued without interruption.
FOCOS-I system contains the following program items in its basic version:
OFF-LINE diffusion program
for simulation and optimization of carburizing programs
Program management
Input of different heat treatment programs, whereby the program sequence can be
divided into up to 10 sections. Option of time and target size control.
Part data bank
Allocation of the individual heat treatment programs for certain parts.
Programmer
Standard value of temperature and C-potential are preset according to the heat
treatment program data and indicated graphically.
ON-LINE diffusion program
During a carburizing program, the current carburizing profile with the carbon
process can be indicated and printed at any time.
At programs with target size control, the carbon process in the heat treatment
material is calculated with the recorded actual values and controlled according to
the target size.
Heat treatment proof
Is available for each charge. It is stored on the hard disk and can be shown on the
screen at any time. It contains the heat treatment program in tabular form with all
relevant part data, the standard and actual values of C-potential and temperatures
in graphic form for the entire process duration, as well as the calculated carbon
process in the parts in tabular form and in a diagram.
Service programs
Calculation of the alloy factor from the composition of the material.
Different conversion functions such as C-levels in probe tension, CO content,
etc.

16

Failure handling
Indication of failures in clear text with time stamp for start and end time.
Help texts
The existing help texts offer valuable support with operation.
Beyond that, there is however still a multiplicity of development stages of the process
control system, which can be extended up to the controlling of a fully automated multi
purpose chamber furnace plant. Then, not only the multi purpose chamber furnaces are
controlled, but all ancillary units get the defaults from the FOCOS system, so that the
complete treatment cycle of a charge is accomplished automatically. The operation of the
plant is limited to charging/discharging of the storage guide rails. In addition to the
already described program items, there is still another multiplicity of software modules
such as teleservice, SMS notification or extended heat treatment proof with laboratory
minutes, which can be adapted to the respective customer requirements.

9.1 Fully automatic Chamber Furnace Line :

Data structure and networking
FOCOS PC
specific printout
by the operator

Master PLC for transport device

and data-distribution /-collection

MP270

Profibus DP

Multi-purpose
chamber furnace

Multi-purpose
chamber furnace

compactcontroller

MP270

MP270

Multi-purpose
chamber furnace

compactcontroller

compactcontroller

Tempering
furnace
750 C
with Nitroc

Tempering
furnace
500 C
with prot.gas

MP270

FLEXICLEAN
degreasing
machine

MP270

FLEXICLEAN

Multi-Purpose Chamber Furnaces

Tempering Furnaces
750 C
with
Nitroc

500 C
with
prot.gas

degreasing
machine

preparative roller path

17

Multi Purpose Chamber Furnace Line

18

AICHELIN Multi-Purpose Chamber Furnace Unit

References

1. Introduction
During the last decades, AICHELIN Group has built far more than 1000 protective gas
chamber furnaces and put them into operation. Most of these plants provide their
service reliably this very day. This impressively proves the permanent high quality,
reliability and economy of these plants. Due to the central meaning of this furnace type,
it is being permanently developed and constantly held together with our customers on
the highest state of the art. This has now resulted in the creation of three series, where
each of them is optimally aligned to your needs. :

Standard-Line

The low cost series with superior components.

Further description within this folder.

Individual-Line

Powerful and worth every Cent. If the standard line does not meet your requirements at
100%. Also described here

Evolution-Line

The series, that fits into EVERY existing chamber furnace plant. Description see separate
folder.

2. Application range of the Multi-Purpose

Chamber Furnace

Gas Carburizing

C
Temperature

Possible modes of heat treatment:

For example:
! gas carburizing
- with direct quenching
- with intermediate cooling
- with charge cooling under
protective gas
! re-carburizing
! carbonitriding
! NITROC - nitrocarburizing
! nitriding
! hardening in oil or salt
! normalizing
! annealing
! tempering

C-Level

t
C

Gas Carburizing with Intermediate Cooling

Temperature
C-Level

t
Annealing

Normalizing
Various annealing programs

Temperature

Temperature

C-Level

When are Chamber Furnaces preferentially used?

!
!
!
!
!
!
!
2

for small and middle capacities

for different heat treatment procedures
for different kind of parts and high diversity of parts
at charge weights of appr. 150 - 1800 kg (even more in special cases)
if flexibility is required
for different production requirements
if quality with economy is required

19

Multi-Purpose Chamber Furnace Unit

Multi-Purpose Chamber Furnace Unit

The Universal Heat Treatment Plant

The Universal Heat Treatment Plant

AICHELIN Ges.m.b.H.
Postfach 210
A-2340 Mdling
Phone (+43) (2236) 236 46 - 0
Telefax (+43) (2236) 22 22 9
info@aichelin.at

NOXMAT GmbH
Ringstrae 7
D-09569 Oederan
Phone (+49) (37292) 65 03-0
Telefax (+49) (37292) 65 03-29
info@noxmat.de

SAFED SUISSE SA
36, rue Emile-Bochat
CH - 2800 Delmont
Phone (+41) (32) 421 44 60
Telefax (+41) (32) 421 44 64
contact@safed.ch

AICHELIN Service GmbH

Postfach 340
D-71603 Ludwigsburg
Phone (+49) (7141) 6437 - 0
Telefax (+49) (7141) 6437 - 100
info@aichelin.de

AICHELIN Heat Treatment

Systems (Beijing) Co. Ltd.
10 00 86 Beijing, China
Phone (+86) (10) 8255 1421
Telefax (+86) (10) 8255 1020
aichelin@china.com

EMA Indutec GmbH

Petersbergstrasse 9
D-74909 Meckesheim
Phone (+49) (6226) 788 - 0
Telefax (+49) (6226) 788 - 100
info@ema-indutec.de

Standard-Line
Individual-Line

http://www.aichelin.com
Subject to technical changes
AICHELIN, NOXMAT, NITROC, ENDOMAT, FLEXICLEAN
are registered trademarks

TI02-01/Mrz2010/E